Abstract: Cast material rotor (200,300,500,800) with profiled helical outer surface (208,308,508,808). Cast material layer (502,802) can be disposed between core (504,804) and tube (506,806). Profiled helical outer surface (208,308) can be in tube 206 or cast material layer 302, respectively. Method of forming rotor 200 can include filling void between outer surface 212 of core 204 and longitudinal bore 210 of tube 206 having profiled helical outer surface 208 with cast material 202 in fluid state, and solidifying cast material 202. Tube 206 can be disposed within profiled helical bore 714 of mold 700, e.g., before solidifying cast material 202. Method of forming rotor 300 can include filling void between outer surface 312 of core 304 and profiled helical bore 714 in mold 700 with cast material 302 in fluid state, solidifying cast material 302 to impart profiled helical outer surface 308 thereto, and removing mold 700 from cast material 302.

Abstract: The present invention recites a method and apparatus, wherein said methods and apparatus comprises an actuator comprising a first plate, a pocket extending through the first plate, the pocket in fluid communication with a pressurized fluid source and a second plate coupled to a component that is to be actuated, wherein the first plate, the second plate, and the pocket are dimensioned such that when a pressurized fluid is discharged through the pocket, the velocity of the fluid through a gap between the first plate and the second plate creates a pressure drop sufficient to pull the second plate toward the first plate.

Abstract: A steerable system comprises a fluid powered motor 10 having a rotor 16 and a stator 18, and a bias arrangement having a plurality of bias pads 34 connected to the stator 18 so as to be rotatable therewith, the bias pads 34 being moveable to allow the application of a side load to the steerable system.

Abstract: A steerable drilling system includes a drill string carrying a bent housing, the bent housing containing or having associated therewith a drive motor arranged to drive a drive shaft angled to an axis of part of the drill string adjacent the bent housing, and an orientating motor permitting relative rotation between the drill string and the bent housing, the orientating motor driving the output shaft in a reverse direction relative to a direction of rotation of the drill string to form a curve in a borehole being formed.

Abstract: The present invention provides means to extend the flow rate range over which a downhole turbine 70 will return a power output sufficient to meet the minimum downhole power requirements. In one embodiment, the present invention relates to an arrangement of axial vanes 77 that are situated such that the rotation of the rotor 76 generates an increasing drag force, thereby extending the upper limit of the flow rate range. In another embodiment, the present invention relates to an arrangement of restriction assemblies 75 that can be used to maximize the fluid velocity relative to the fluid flow rate past the stator 74 to achieve the necessary speed and power to rotate rotor 76, thereby extending the lower limit of the flow rate range. In another embodiment, the axial vanes 77 and restriction assemblies 75 are used in combination to further extend both the upper and lower limits of the flow rate range of the downhole turbine 70.

Abstract: The invention provides rotary steerable devices and methods for use of rotary steerable devices. One aspect of the invention provides a rotary steerable device including: a cylinder configured for rotation in a wellbore, the cylinder having a slot and a gauge; and at least one cam received in the slot. The cam is configured for selective actuation between a first position, wherein the cam lies within the gauge of the cylinder, and a second position, wherein the cam is displaced out of the gauge of the cylinder.

Abstract: The present invention relates to systems and methods for controlling downhole motors and drilling systems incorporating such systems and methods. One aspect of the invention provides a downhole drilling system including: a downhole motor, a transmission coupled to the downhole motor, and a drill bit coupled to the transmission. Another aspect of the invention provides a method of drilling a borehole in a subsurface formation including the steps of: providing a drill string including a downhole motor, a transmission coupled to the downhole motor, and a drill bit coupled to the transmission; and rotating the drill string while flowing a fluid through the drill string to the downhole motor, thereby powering the downhole motor, thereby rotating the transmission and the drill bit.

Abstract: Hydrostatic bearings are used for drill string stabilization and bottom hole assembly steering. The hydrostatic bearings utilize an existing mud flow as the bearing fluid. For steering, the bearings may be used between movable kick pads and the formation to reduce friction. Alternatively, differential hydrostatic bearing pressure may be utilized to steer. Multi-modal (non-linear and linear) steering may be provided by selectively applying equal and unequal hydrostatic bearing pressures. The bearings can be made more tolerant of imperfections in the formation by utilizing multiple pressure pockets.

Abstract: The present invention relates to a stator (100-1000) with a profiled helical bore (106,206,306,606,706,806,906,1006) having a cast material layer (102;202;302;602;702;802;902;1002) with transducers (104A-104D;304;604A-604D;710;804;904A-904C;1010) disposed therein and describes the methods of forming such stators. Cast material can be fluidic during displacing of a transducer therein. Cast material layer 202 can include housings (218,222) disposed therein and/or a cavity 226 formed therein. Transducer can be a sensor (104A-104C) and/or an actuator 104D. Transducer 804 can extend axially along a length of the stator 800. Transducer or plurality of transducers (904A-904C) can extend along a helical path. Additionally or alternatively, sleeve 1008 can include a transducer 1010.